U.S. patent application number 13/715503 was filed with the patent office on 2014-06-19 for led module for light distribution.
The applicant listed for this patent is David Gershaw. Invention is credited to David Gershaw.
Application Number | 20140168955 13/715503 |
Document ID | / |
Family ID | 50930657 |
Filed Date | 2014-06-19 |
United States Patent
Application |
20140168955 |
Kind Code |
A1 |
Gershaw; David |
June 19, 2014 |
LED MODULE FOR LIGHT DISTRIBUTION
Abstract
Devices, systems, and methods are provided for achieving
desirable light distributions. In one exemplary embodiment, the
light module includes a body having a pair of opposed complex
parabolic bodies, an LED light source, and an inner reflective
surface. The light source can be configured to provide for a
desired light distribution, such as a bat wing light distribution.
The provided light distribution can be such that it is not the
result of passing light through a secondary optics component. Thus,
while in some embodiments the LED module can include a glare
reduction lens disposed over at least part of the LED light source,
the lens may not affect the resulting light distribution
configuration. Exemplary configurations of other systems, devices,
kits, and methods associated with the teachings are also
provided.
Inventors: |
Gershaw; David; (Danvers,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gershaw; David |
Danvers |
MA |
US |
|
|
Family ID: |
50930657 |
Appl. No.: |
13/715503 |
Filed: |
December 14, 2012 |
Current U.S.
Class: |
362/147 ;
362/225 |
Current CPC
Class: |
F21S 8/026 20130101;
F21V 13/04 20130101; F21Y 2103/10 20160801; F21Y 2115/10
20160801 |
Class at
Publication: |
362/147 ;
362/225 |
International
Class: |
F21V 7/00 20060101
F21V007/00; F21V 14/02 20060101 F21V014/02; F21V 14/00 20060101
F21V014/00; F21V 13/04 20060101 F21V013/04; F21S 8/04 20060101
F21S008/04 |
Claims
1. An LED module, comprising: a linear optical body having opposed
first and second complex parabolic bodies, each inner surface of
the parabolic bodies being configured to reflect light; a first
circuit board having at least one LED disposed thereon and mounted
to the first complex parabolic body; and a second circuit board
having at least one LED disposed thereon and mounted to the second
complex parabolic body, wherein a distribution of light from the at
least one LED of the first circuit board and the at least one LED
of the second circuit board has a bat wing distribution that is not
the result of passing light through a secondary optics
component.
2. The LED module of claim 1, further comprising a reflective
diffuser mounted on an inner surface of the linear optical
body.
3. The LED module of claim 1, wherein a first angle formed by a
central axis of the first complex parabolic body and a central axis
of the linear optical body is approximately in the range of about
15 degrees to about 60 degrees, and a second angle formed by a
central axis of the second complex parabolic body and the central
axis of the linear optical body is approximately in the range of
about 15 degrees to about 60 degrees.
4. The LED module of claim 3, wherein the first angle and the
second angle are both approximately 30 degrees.
5. The LED module of claim 1, further comprising a glare reduction
lens mounted over at least the LEDs of the first and second circuit
boards.
6. The LED module of claim 1, further comprising a first fin
extending in a generally transverse direction from the first
complex parabolic body and a second fin extending in a generally
transverse direction from the second complex parabolic body.
7. The LED module of claim 6, wherein an angle formed by at least
one of the first and second fins and a transverse plane extending
across a bottom of the linear optical body is greater than
zero.
8. The LED module of claim 6, further comprising an accessory mount
coupled to the first and second fins and extending above the linear
optical body.
9. The LED module of claim 6, further comprising one or more
sideways-mounted LEDs disposed below the first and second fins and
configured to illuminate by a battery source.
10. The LED module of claim 1, further comprising a thin panel
coupled to the linear optical body.
11. The LED module of claim 10, further comprising one or more
mounting features extending transversely from opposed sides of the
thin panel.
12. The LED module of claim 1, further comprising a ceiling tile
coupled to the linear optical body.
13. The LED module of claim 1, wherein the first and second circuit
boards are mounted along a central axis of the first and second
complex parabolic bodies.
14. The LED module of claim 1, wherein the first and second circuit
boards are mounted between central axes of the first and second
complex parabolic bodies and the respective inner walls of the
first and second complex parabolic bodies.
15. The LED module of claim 14, wherein the first and second
circuit boards are mounted on the respective inner walls of the
first and second complex parabolic bodies.
16. The LED module of claim 1, wherein the first and second circuit
boards are mounted between central axes of the first and second
complex parabolic bodies and the respective outer walls of the
first and second complex parabolic bodies.
17. A method for distributing light, comprising: positioning a
panel coupled to a light source in a ceiling, the light source
having a linear optical body and one or more LEDs coupled thereto;
directing light from the light source to a location below the
ceiling in a bat wing distribution configuration that is not the
result of passing the light through a secondary optics
component.
18. The method of claim 17, further comprising adjusting at least
one of a size and a shape of the linear optical body to adjust the
bat wing distribution configuration to a desired configuration.
19. The method of claim 18, wherein the linear optical body
comprises a plurality of complex parabolic bodies, the method
further comprising adjusting at least one of a size of the
plurality of complex parabolic bodies and angles formed by the
complex parabolic bodies relative to a transverse plane extending
across a bottom of the linear optical body to adjust the bat wing
distribution configuration to a desired configuration.
20. The method of claim 17, further comprising adjusting a location
of the one or more LEDs relative to the linear optical body to
adjust the bat wing distribution configuration to a desired
configuration.
Description
FIELD
[0001] The present disclosure relates to LED lighting systems that
produce light visible to the human eye. More particularly the
disclosure relates to improved devices, kits, and methods for
either retrofitting existing overhead lighting systems or
installing new overhead lighting systems. The disclosure also
relates to improved devices, systems, and methods for distributing
light. Although the disclosures contained herein are primarily
directed to the installation of lighting systems in conjunction
with drop down ceilings, those skilled in the art will appreciate
the disclosures herein can be adapted for use with a number of
other types of ceilings and other structures, fixtures, materials,
and components. Likewise, those skilled in the art will appreciate
the applicability of the present application with respect to a
variety of applications such as general purpose, decretive,
ornamental, special effects, automotive lighting, and other.
BACKGROUND
[0002] Typically, drop down ceilings, such as the one illustrated
in FIG. 1, are used in many commercial and residential building
projects when the height of the desired ceiling is lower than the
structures actual ceiling height. The drop down ceiling is built
using a metal grid which is supported by cables to the actual
building. The grid is than populated with ceiling tiles, HVAC ducts
and lighting. Such grids have been standardized to 2.times.2 foot
and 2.times.4 foot sizes in order to make it easier for
manufactures of ceiling tiles, HVAC ducts and lighting fixtures to
offer standard products.
[0003] Lighting fixtures in the 2.times.2 foot and 2.times.4 foot
sizes have for many years been illuminated using linear fluorescent
lamps. These fixtures are sometimes referred to as fluorescent
troffers. A fluorescent troffer can include components such as a
sheet metal enclosure, a fluorescent ballast, fluorescent lamps and
optics to shape the light emitted from the lamps into something
pleasing for the environment in which it will be used. A person
skilled in the art will recognize three typical types of
fluorescent troffers: prismatic, parabolic, and volumetric. One
example of a prismatic troffer is illustrated in FIG. 2, and can
include, for example, lamps recessed inside the fixture with a lens
covering the face of the fixture. One example of a parabolic
troffer is illustrated in FIG. 3, and can include, for example,
lamps recessed behind or inside cells with no lens covering the
fixture. One example of a volumetric troffer is illustrated in FIG.
4, and can include, for example, lamps inside of specially designed
reflectors and lenses.
[0004] The overall foot print of the various choices of fluorescent
troffers, including but not limited to the three main types
described herein, are generally the same because they must all drop
into 2.times.2 foot or 2.times.4 foot grids.
[0005] While efforts to make more efficient lighting have led to
developments directed to upgrading and replacing fluorescent
troffers, such efforts suffer from a number of deficiencies. For
example, some efforts that leave existing troffers in place do not
improve the overall appearance of the light generated as the old
troffers often remain old and dirty. In fact, light that used to be
pleasing and have a low glare may be adversely affected.
Additionally, because older systems are designed to be used with
older technology, the optical efficiency (Lumens per Watt) that
exists with newer technology can be lost due to compatibility
issues. The optical efficiency (Lumens per Watt) of the total
system can be lower than replacement components, or even the old
components, and thus the total luminance of the lit space can
decrease. Still further, complications can often arise in the
re-wiring and re-fitting that is often needed to marry the newer
systems with the older systems. Existing retrofitting options can
be unreliable at least because the newer components may not fit
well with the older components, and the cost associated with
purchasing and installing the more efficient lighting can be
expensive. New, replacement fixtures are also expensive and can
suffer from many of the same complications already discussed.
Additional complications can stem from new, replacement fixtures
because the ceiling in which the new, replacement fixtures are
installed may require modifications to handle different loads.
[0006] By way of non-limiting example, one way lighting fixtures
having fluorescent tubes are modified to included an LED solution
is by replacing the tube with an LED tube having the appropriate
sized to fit into the existing fluorescent troffer fixture. The LED
tube typically exhibits a Lambertian candela light distribution, as
illustrated in FIG. 5. When the LED tube is added to the troffer
fixture without any optics, the resulting light distribution from
the troffer can also be Lambertian. A person skilled in the art
will recognize that Lambertian light distribution is not generally
desirable for office-type lighting. Rather, bat wing light
distribution, as illustrated in FIG. 6, is more preferable for
office environments. Prior to the present disclosure, attempts to
achieve bat wing light distribution involved associating secondary
optics components with the troffers in which the LED tubes were
installed to assist in creating the desired light distribution.
Examples of such secondary optics components include a prismatic
lens, baffles, or parabolic cells. These attempts, however,
particularly in a retrofit setting with LED tubes, were not able to
achieve a desirable light distribution. The amount of light for a
particular space was often insufficient and included an undesirable
amount of glare.
[0007] The present disclosure contemplates new and improved
devices, kits, and methods for either retrofitting existing
overhead lighting systems, or providing new overhead lighting
systems that are easier and cheaper to install, perform more
efficiently, and minimize and/or overcome many of the
aforementioned deficiencies. The present disclosure also
contemplates new and improved devices, systems, and methods for
improving the distribution of light emanating from a light
fixture.
SUMMARY
[0008] The present disclosure relates to a new category of
fluorescent troffer replacement. This new category is called
"drop-in below troffer panel lighting." As described herein, the
"drop-in below troffer panel lighting" can retain the fluorescent
fixture in its entirety (including the fixture, lamps, ballast),
and can include a thin, light weight plastic (or other material)
panel with integrated LED lighting system built in. This panel can
be easily installed below the existing fluorescent fixture (or
inside for prismatic lensed troffers) and can provide for many
benefits.
[0009] The present disclosure also relates to a new category of
troffer that includes an LED light source and can be used as a new,
"ceiling tile integrated lighting system." As described herein, the
devices, kits, and methods can include, for example, a very thin
panel to be used in a retrofit situation, or can be integrated into
existing manufactured ceiling tiles for new installations.
[0010] Still further, the present disclosure relates to devices,
systems, and methods for creating a linear LED light source with a
bat wing candela light distribution without the assistance of
secondary optics components. Other desirable light distributions
created without the assistance of secondary optics components are
also contemplated. As a result, the LED light sources provided
herein can be used without having secondary optics components
disposed over top of the LED light source. Alternatively, to the
extend secondary optics components are used in conjunction with LED
light sources provided for herein, the secondary optics components
can be used for purposes other than forming a desired light
distribution configuration, such as to reduce glare or intensity.
In one embodiment, the linear LED light source includes LEDs
mounted to a circuit board. The circuit board can be attached to a
linear optical cavity. The linear optical cavity can include one or
more walls that are coated, extruded, or layered to have a highly
reflective surface, such as a specular (minor-type) surface or a
diffuser having a reflectively that is approximately equal to or
greater than 98%. The linear optical cavity can be made of a
variety of materials, including polymers, plastic, metal, metal
alloys, and other materials used by those skilled in the art for
bending, extruding, and thermoforming. Multiple linear optical
cavities can be connected and oriented at various angles with
respect to each other to achieve a desired light distribution, such
as a bat wing light distribution. A number of factors can impact
the resulting light distribution, including but not limited to a
size of a complex parabolic body of the light source and the
positioning of LEDs along an extrusion axis of the complex
parabolic body. As demonstrated herein, there is a unique
correlation of the rotated angle of the complex parabolic body and
the LED linear positioning along the extrusion axis of the complex
parabolic body that can allow for the creation of desired light
distributions, including a bat wing candela distribution.
[0011] Benefits of the present disclosure include, but are not
limited to: [0012] The existing troffer and fluorescent tubes can
be left in place, thereby removing the need for costly and time
consuming disposal. [0013] The old, dirty fluorescent troffer can
be covered up. While the fixture can still be in the ceiling,
visually the occupants of the lit space will only see a sparkling
new modern looking panel that was installed under the old fixture.
This can create a better and more productive environment for those
occupants using the lit space. [0014] High fixture efficiency.
Because the fixture is designed from scratch to take advantage of
LED, the fixture can have the highest possible Lumens per Watt
efficiency. [0015] There are no safety related issues. The fixture
is designed from scratch to correctly provide safety features
specific to LED technology. There is no anticipated risk of a
future maintenance person attempting to install fluorescent tubes
when components associated with the present disclosure are in
place. [0016] Light output and distribution can be very well
designed. [0017] Glare. The system can be designed to properly
reduce or control glare. [0018] Reliability. Because the designs
described herein can include ample room for proper thermal
management, the system can run in safe temperature ranges for the
long period of life of the LED and the driver. [0019] Inexpensive
cost and simple build. In some embodiments, almost the entire
lighting system can be made of plastics. Thermal management can be
handled at the LED level by running extremely efficient (120LPW+)
LEDs at low currents (0-100 mA), and thus additional thermal
management is not generally required. In some embodiments, LEDs can
be mounted on MPCB, FR4 or even plastic circuits printed with
electrically conductive inks, thereby providing further cost
savings. The extremely low number of parts on the bill of materials
makes this extremely cost effective to manufacture. [0020] Easy to
install because the components of the devices and kits described
herein can fit into existing ceiling grid. [0021] In embodiments
that primarily rely upon plastic construction, the systems are
durable and non-fragile. [0022] Simplicity of
transportation/installation. Because these systems can be extremely
light weight, they can be very easy items to package efficiently
and transport inexpensively. In addition, the light weight design
can make them easy to install for someone standing on top of a
ladder. A risk of dropping the LED fixture during the assembly is
very small. And if it does fall, it will most likely not sustain
any damage.
[0023] A person skilled in the art will recognize that there are
many methods by which this invention can be carried out, and thus
to the extent the present disclosure focuses on a particular method
and associated variations for description purposes, such method is
in no limits the scope of the invention. No preference has been
taken to the selection of choosing to describe this method, since
the main goal of this application is the concept of either a panel
containing an integrated luminaire that will reside below or inside
an existing fluorescent troffer or integrating the same luminaire
inside of a ceiling tile. A person skilled in the art would be able
to come up with additional modes for carrying out this invention
without departing from the spirit of the present disclosure.
[0024] In one exemplary embodiment a method for installing a
lighting element in a pre-installed troffer can include selecting a
thin panel that is sized to fit an opening of the troffer. The
panel can also have at least one LED module integrated therewith.
The method can further include removing electrical enclosures of
the troffer to provide access to electrical connections. This can
result in the troffer serving as a junction box. The at least one
LED module can be electrically connected to the electrical
connections, after which at least a portion of the removed
electrical enclosures of the troffer can be re-installed if
desired. The thin panel with which the LED module is associated can
then be positioned at or below a bottom portion of the troffer. In
some embodiments, a driver can be mounted adjacent to the thin
panel and electrically connected to the LED module. In other
embodiments the driver can be integrated with the LED module prior
to installation of the panel. An installer can disconnect a line
potential from a ballast of the troffer. Further, in some
embodiments a weight of the thin panel and the at least one LED
module can be negligible such that a cabling system associated with
the troffer does not require adjustment to account for additional
weight of the light fixture.
[0025] In another exemplary embodiment a method for installing a
light fixture can include selecting a ceiling tile having at least
one LED module integrated therewith, electrically connecting the at
least one LED module to electrical connections disposed adjacent to
a ceiling grid, and positioning the ceiling tile in the grid. In
some embodiments the ceiling tile can have a junction box
integrated therewith, with the junction box being configured to be
part of the electrical connections made between the at least one
LED module and the electrical connections disposed adjacent to the
ceiling grid. A location of the ceiling tile can be selected such
that it is adjacent to a junction box, and then the junction box
can be used to make electrical connections between the at least one
LED module and the electrical connections disposed adjacent to the
ceiling grid. Further, in some embodiments a weight of the ceiling
tile and the at least one LED module can be negligible such that a
cabling system associated with the ceiling tile does not require
adjustment to account for additional weight of the ceiling tile and
the at least one LED module.
[0026] One exemplary embodiment of a light fixture can include a
thin panel, at least one LED module integrated with the thin panel,
and a troffer. The LED module can have an LED package in electrical
communication with a driver, the LED package can be mounted to a
circuit board, and a lens can be coupled to at least one of the
circuit board and the LED package. The troffer can have a top, a
bottom, and a ballast compartment, with the bottom having an
opening through which light can pass, and the ballast compartment
having a configuration to provide electrical connections to the
driver and the LED package. The thin panel can be configured to
mate to the troffer to cover at least a portion of the opening of
the troffer such that light from the LED module is directed through
the lens of the LED module from a location that is below the top of
the troffer. In some embodiments, the driver can be disposed within
the LED module, while in other embodiments the driver can be remote
from the LED module. The LED module can include optics configured
to assist in focusing light emanating from the LED module and/or
assist in reducing glare from light emanating from the LED module
and/or assist in reducing hot spots of the LED module. Further, a
diffuser can be included, with the diffuser being configured to
assist in reducing glare from light emanating from the LED module.
In some embodiments, the LED module can be made completely of
plastic.
[0027] Another exemplary embodiment of a light fixture can include
a ceiling tile having a front face and a back face, at least one
LED module mounted to the front face of the ceiling tile, and a
junction box located proximate to the back face of the ceiling
tile. The LED module can include an LED package in electrical
communication with a driver, with the LED package being mounted to
a circuit board, and a lens coupled to at least one of the circuit
board and the LED package. The junction box can be configured to
provide electrical connections to the driver and the LED package.
Further, electrical power can be provided to the junction box, and
thus to the driver and the LED package, such that light from the
LED module is directed through the lens to an outside environment.
In some embodiments the driver can be disposed within the LED
module, which in other embodiments the driver can be located remote
from the LED module, for instance proximate to the back face of the
ceiling tile. The LED module can include optics configured to
assist in focusing light emanating from the LED module and/or
assist in reducing glare from light emanating from the LED module
and/or assist in reducing hot spots of the LED module. Further, a
diffuser can be included, with the diffuser being configured to
assist in reducing glare from light emanating from the LED module.
In some embodiments, the LED module can be made completely of
plastic.
[0028] An exemplary embodiment of a kit for installing a light
fixture can include one or more thin panels and/or one or more
ceiling tiles, as well as at least one LED module configured to be
integrated with either or both of the panels and tiles and an
instruction manual. The at least one LED module can have an LED
package in electrical communication with a driver, the LED package
can be mounted to a circuit board, and a lens can be coupled to at
least one of the circuit board and the LED package. In kits that
include one or more thin panels, the instruction manual can include
directions for installing the one or more thin panels integrated
with the at least one LED module over a troffer. In kits that
include one or more ceiling tiles, the instruction manual can
include directions for installing the one or more ceiling tiles
integrated with the at least one LED module in a ceiling grid. The
instruction manual can include both types of directions as well.
The directions can be based, at least in part, on the methods
disclosed herein for installing a light fixture in conjunction with
a thin panel and/or a ceiling tile.
[0029] In accordance with one method of carrying out this
invention, a method of design for such a panel is disclosed. A
choice of LED module is chosen. A plastic panel or ceiling tile is
chosen. The LED module can be integrated onto the plastic panel or
ceiling tile. The installation in the field for the retrofit can
include, for example, first removing the prismatic lens or
releasing the parabolic of volumetric enclosure. Next the enclosure
on the existing fluorescent troffer can be removed, thereby
providing the installer access to the electrical connections. The
line potential can be disconnected from the fluorescent ballast.
The new LED driver can be mounted near the fluorescent ballast. A
person skilled in the art will recognize that in embodiments in
which the LED panel has an integrated driver, the step of mounting
the LED driver near the fluorescent ballast can be omitted. The
cable from the LED driver can be allowed to hang down through the
fixture and the original electrical enclosure can be re-installed.
In the case of a prismatic lensed troffer, the prismatic lens can
be removed and disposed of and the LED panel can be installed in
its place. In the case of any other style fluorescent troffer, the
LED panel can be installed below the existing fixture between the
supporting ceiling grid and the existing fixture. In the case of
new installation in accordance with the present disclosure, the LED
module is chosen, a ceiling tile is chosen, and a junction box is
chosen. The LED module can be integrated into the ceiling tile. The
junction box can also be integrated into the ceiling tile. The
installation in the field for the new installation can include,
first making the necessary electrical connections and then dropping
the LED panel into the ceiling grid. A person having skill in the
art will understand other types of steps that can be necessary to
perform in order to perform either a retrofit or a new installation
in accordance with the present disclosure.
[0030] One exemplary embodiment of an LED module can include a
linear optical body having opposed first and second complex
parabolic bodies, a first circuit board having at least one LED
disposed thereon and mounted to the first complex parabolic body,
and a second circuit board having at least one LED disposed thereon
and mounted to the second complex parabolic body. A distribution of
light from the at least one LED of the first circuit board and the
at least one LED of the second circuit board can have a bat wing
distribution that is not the result of passing light through a
secondary optics component, i.e., the resulting distribution is not
affected by any secondary optics component. A person skilled in the
art will recognize that other desirable light distributions that
are not necessarily bat wing distributions can also be achieved. A
distribution of light as described herein generally refers to
directing light to particular locations and/or not directing light
to other particular locations as desired, and is referenced herein
interchangeably at least as a distribution of light, light
distribution, and light distribution configuration. Thus, as
described, secondary optics components do not substantially change
the location of where light is directed and where light is not
directed. Each inner surface of the parabolic bodies can be
configured to reflect light. In some embodiments the inner surfaces
can be coated with a reflective material. In other embodiments a
reflective diffuser can be mounted on an inner surface of the
linear optical body. In still other embodiments the inner surface
can be part of a highly reflective extruded material.
[0031] A first angle formed by a central axis of the first complex
parabolic body and a central axis of the linear optical body can be
approximately in the range of about 15 degrees to about 60 degrees,
and a second angle formed by a central axis of the second complex
parabolic body and the central axis of the linear optical body can
be approximately in the range of about 15 degrees to about 60
degrees. In one embodiment the first angle and the second angle are
both approximately 30 degrees. A glare reduction lens can be
mounted over at least the LEDs of the first and second circuit
boards. Although a glare reduction lens can be a secondary optics
component, a person skilled in the art will recognize it does not
substantially change a location of where light is directed and
where light is not directed. In some embodiments a first fin can
extend in a generally transverse direction from the first complex
parabolic body and a second fin can extend in a generally
transverse direction from the second complex parabolic body. An
angle formed by at least one of the first and second fins and a
transverse plane extending across a bottom of the linear optical
body can be greater than zero. Alternatively, the first and/or
second fins can extend substantially parallel to or collinear with
the transverse plane extending across the bottom of the linear
optical body. Another feature of the LED module can be an accessory
mount coupled to the first and second fins. In some embodiments the
accessory mount can extend above the linear optical body. Yet
another feature of the LED module can be one or more
sideways-mounted LEDs disposed below the first and second fins. The
sideways-mounted LEDs can be configured to illuminate by a battery
source. Such sideways-mounted LEDs can be useful, for example, in
emergency situations.
[0032] The first and second circuit boards can be mounted in a
variety of configurations. In some embodiments the first and second
circuit boards can be mounted along a central axis of the first and
second complex parabolic bodies. In some other embodiments the
first and second circuit boards can be mounted between central axes
of the first and second complex parabolic bodies and the respective
inner walls of the first and second complex parabolic bodies. For
example, the first and second circuit boards can be mounted on the
respective inner walls of the first and second complex parabolic
bodies. In still some other embodiments the first and second
circuit boards can be mounted between the central axes of the first
and second complex parabolic bodies and the respective outer walls
of the first and second complex parabolic bodies. A person skilled
in the art will recognize that these circuit board locations can be
mixed and matched to create additional light distribution options,
either with the described mounting configurations or other
potential mounting configurations derivable based on the teachings
provided herein.
[0033] The LED module can be coupled to a thin panel or a ceiling
tile. In some embodiments one or more mounting features can extend
transversely from opposed sides of the thin panel. Such features
can assist in mounting the thin panel in a ceiling grid.
[0034] An exemplary method for distributing light can include
positioning a panel coupled to a light source in a ceiling and
directing light from the light source to a location below the
ceiling in a bat wing distribution configuration that is not the
result of passing the light through a secondary optics component.
The light source can include a linear optical body and one or more
LEDs coupled thereto. In some embodiments the method can include
adjusting at least one of a size and a shape of the linear optical
body to adjust the bat wing distribution configuration to a desired
configuration. The linear optical body can include a plurality of
complex parabolic bodies. In such instances, the method can include
adjusting at least one of a size of the plurality of complex
parabolic bodies and angles formed by the complex parabolic bodies
relative to a transverse plane extending across a bottom of the
linear optical body to adjust the bat wing distribution
configuration to a desired configuration. Additionally, in some
embodiments the method can include adjusting a location of the one
or more LEDs relative to the linear optical body to adjust the bat
wing distribution configuration to a desired configuration. While
secondary optics components can be used in conjunction with the
disclosures herein as a further way to adjust a light distribution,
in some embodiments no secondary components are included as part of
the light source. In some other embodiments, one or more secondary
optics components is included but such component(s) does
substantially change the location of where light is directed and
where light is not directed. In still other embodiments the
secondary optics components can provide further adjustment of the
desired light distribution configuration.
[0035] The advantages of the present application include improved
methods, devices, systems, and kits for either new or retrofit
2.times.2 foot, 2.times.4 foot, or other sizes for that matter, of
lighting a space with overhead ceiling grid, and improved methods,
devices, systems, and kits for providing desirable light
distributions.
BRIEF DESCRIPTION OF DRAWINGS
[0036] The application may take form in various components and
arrangements of components, and in various steps and arrangements
of steps. The drawings are only for purposes of illustrating the
preferred embodiments and are not to be construed as limiting the
application. This invention will be more fully understood from the
following detailed description taken in conjunction with the
accompanying drawings, in which:
[0037] FIG. 1 is an isometric view of a ceiling grid with a
fluorescent fixture installed as known in the prior art;
[0038] FIG. 2 is an isometric view of a prismatic fluorescent
fixture as known in the prior art;
[0039] FIG. 3 is an isometric view of a parabolic fluorescent
fixture as known in the prior art;
[0040] FIG. 4 is an isometric view of a volumetric fluorescent
fixture as known in the prior art;
[0041] FIG. 5 is a schematic view of a Lambertian light
distribution as known in the prior art;
[0042] FIG. 6 is a schematic view of a bat wing light distribution
as known in the prior art;
[0043] FIG. 7A is a side profile view of one exemplary embodiment
of a thin panel or ceiling tile;
[0044] FIG. 7B is an isometric view of the thin panel or ceiling
tile of FIG. 7A;
[0045] FIG. 8 is a side profile view of exemplary embodiments of
differently shaped LED modules;
[0046] FIG. 9 is a side profile view of the LED modules of FIG. 8
integrated with the thin panel or ceiling tile of FIGS. 7A and
7B;
[0047] FIG. 10 is an exploded view of one exemplary embodiment of
an LED module and related components;
[0048] FIG. 11 is an isometric view of an exemplary embodiment of a
linear optical body for inclusion as part of an LED module;
[0049] FIGS. 12A-12D are schematic diagrams illustrating one
exemplary embodiment for forming a linear optical body having
complex parabolic surfaces for use in conjunction with an LED
module;
[0050] FIG. 12E is a schematic diagram of a side profile of the
linear optical body of FIG. 11, which results from a process
associated with FIGS. 12A-12D;
[0051] FIG. 13 is a side profile view of the linear optical body of
FIG. 11, the body having an inner reflective surface;
[0052] FIG. 14 is a side profile view the linear optical body of
FIG. 13, the body having a linear LED light source associated
therewith;
[0053] FIG. 15A is a side profile view of one exemplary embodiment
of a linear optical body illustrating one possible location for an
LED light source;
[0054] FIG. 15B is a schematic diagram illustrating a light
distribution resulting from the configuration of the linear optical
body of FIG. 15A;
[0055] FIG. 16A is a side profile view of another exemplary
embodiment of a linear optical body illustrating another possible
location for an LED light source;
[0056] FIG. 16B is a schematic diagram illustrating a light
distribution resulting from the configuration of the linear optical
body of FIG. 16A;
[0057] FIG. 17A is a side profile view of yet another exemplary
embodiment of a linear optical body illustrating yet another
possible location for an LED light source;
[0058] FIG. 17B is a schematic diagram illustrating a light
distribution resulting from the configuration of the linear optical
body of FIG. 17A;
[0059] FIG. 18A is a side profile view of still another exemplary
embodiment of a linear optical body illustrating still another
possible location for an LED light source;
[0060] FIG. 18B is a schematic diagram illustrating a light
distribution resulting from the configuration of the linear optical
body of FIG. 18A;
[0061] FIG. 19A is a side profile view of another exemplary
embodiment of a linear optical body illustrating another possible
location for an LED light source;
[0062] FIG. 19B is a schematic diagram illustrating a light
distribution resulting from the configuration of the linear optical
body of FIG. 19A;
[0063] FIG. 20A is a side profile view of yet another exemplary
embodiment of a linear optical body illustrating yet another
possible location for an LED light source;
[0064] FIG. 20B is a schematic diagram illustrating a light
distribution resulting from the configuration of the linear optical
body of FIG. 20A;
[0065] FIG. 21 is an isometric view of the linear optical body of
FIG. 11 having the linear LED light source of FIG. 14 mounted
thereto;
[0066] FIG. 22A is a side profile view of one exemplary embodiment
of a glare reduction lens;
[0067] FIG. 22B is an isometric view of the linear optical body of
FIG. 21 having the glare reduction lens of FIG. 22A incorporated
therewith, the configuration resulting in an exemplary embodiment
of an LED module;
[0068] FIG. 23 is an schematic isometric view of the LED module of
FIG. 22B integrated with the thin panel of FIGS. 7A and 7B to form
an LED panel;
[0069] FIG. 24 is an isometric view of the LED module of FIG. 22B
having fins incorporated therewith;
[0070] FIG. 25 is a partially transparent isometric view of the LED
module of FIG. 24 incorporated with a thin panel;
[0071] FIG. 26 is an isometric view of the LED module of FIG. 10
integrated with the thin panel of FIGS. 7A and 7B to form an LED
panel;
[0072] FIG. 27 is an isometric view of the LED module of FIG. 10
integrated with a ceiling tile to form an LED panel;
[0073] FIG. 28 is an isometric view of one rectangular section of a
ceiling grid;
[0074] FIG. 29 is an exploded view of the one rectangular section
of a ceiling grid of FIG. 28, the rectangular section having an
existing fluorescent fixture, and the LED panel of FIG. 26
associated therewith;
[0075] FIG. 30 is an isometric view of the one rectangular section
of the ceiling grid, the fluorescent fixture, and the LED panel of
FIG. 29 in an installed position;
[0076] FIG. 31 is a side profile view of the one rectangular
section of the ceiling grid, the existing fluorescent fixture, and
the LED panel, all of FIG. 30, illustrating aspects of installation
for a retrofit;
[0077] FIG. 32 is an isometric view of one exemplary embodiment of
a mounting feature associated with the LED panel of FIG. 26;
[0078] FIG. 33 is a side profile view of the one rectangular
section of a ceiling grid of FIG. 16 being associated with the
ceiling tile of FIG. 27 in an installed position;
[0079] FIG. 34 is an isometric view of a ceiling grid with the thin
panel and the LED module of FIG. 26 installed below an existing
fluorescent fixture, or alternatively, with the ceiling tile and
the LED module of FIG. 27;
[0080] FIG. 35 is an isometric view of the LED module of FIG. 10
with a bulb screw base;
[0081] FIG. 36 is an isometric view of the LED module of FIG. 10
with a built in control system; and
[0082] FIG. 37 is a schematic chart illustrating examples of common
standardized lamp bases for use in conjunction with LED modules of
the nature described herein.
DETAILED DESCRIPTION
[0083] Certain exemplary embodiments will now be described to
provide an overall understanding of the principles of the
structure, function, manufacture, and use of the devices and
methods disclosed herein. One or more examples of these embodiments
are illustrated in the accompanying drawings. Those skilled in the
art will understand that the devices and methods specifically
described herein and illustrated in the accompanying drawings are
non-limiting exemplary embodiments and that the scope of the
present invention is defined solely by the claims. The features
illustrated or described in connection with one exemplary
embodiment may be combined with the features of other embodiments.
Such modifications and variations are intended to be included
within the scope of the present invention. By way of non-limiting
example, disclosures directed to ceiling tiles with LED modules and
the installation of a new ceiling tile associated with an LED
module can be easily adapted by a person skilled in the art to be
applicable to disclosures directed to thin panels with LED modules
and the installation of a thin panel associated with an LED module
in conjunction with a retrofit, and vice versa.
[0084] One aspect of the present disclosure relates to systems and
devices that can be used to replace existing overhead lighting, or
which can be used as a new form of overhead lighting. As described
herein, an LED panel light can be mounted on a ceiling tile or on a
thin replacement panel. The disclosures also contemplate a variety
of methods that can be used to replace current light sources with
an LED light source, such as by replacing existing fluorescent
troffer fixtures, and methods for installing new light sources
where light fixtures previously did not exist.
[0085] Another aspect of the present disclosure relates to systems
and devices that can be used in conjunction with improving the
distribution of light from lighting sources, such as LED modules.
The LED modules described herein allow for a variety of desirable
light distribution configurations to be created without using
secondary optics components. Although the present disclosure
primarily discusses LED light sources, a person skilled in the art
will understand that these disclosures can also be applied to
Lambertian light sources. Further, a person skilled in the art will
recognize various types of secondary optics components, which
include but are not limited to various types of lenses. The size,
shape, and general configuration of linear optical bodies or
cavities of the modules can be adjusted to affect the light
distribution. Additionally, or in lieu of, a size, shape,
configuration, and general location of LEDs associated with the
linear optical bodies or cavities can be adjusted to affect the
light distribution.
[0086] While the present description and figures primarily discuss
the light sources described herein as being used in overhead
lighting in conjunction with a ceiling grid, a person skilled in
the art will recognize that the light sources disclosed herein, and
methods related to the same, can be used in various other ceiling
constructions, as well as across a number of other industries in a
variety of different configurations. Accordingly, the disclosures
herein are not limited to uses in ceilings. By way of non-limiting
examples, the light sources described herein can be incorporated
into walls, floors, or stand-alone components that provide light,
such as billboards and signs. Additionally, a person skilled in the
art will recognize that although the devices, systems, kits, and
methods discussed herein are primarily discussed with respect to
ceiling grid lighting, the disclosed devices and methods can also
be used in conjunction with manufacturing new devices and systems
in any number of industries.
[0087] In the following description, well-known functions or
constructions are not described in detail to avoid obscuring the
main subjects of the disclosure in unnecessary detail.
[0088] With reference to FIGS. 7A and 7B, an illustration of a thin
panel 08 is shown. As made clear by descriptions herein, the thin
panel 08 can also be a ceiling tile. The thin panel 08 can be
configured in a manner that is complementary to the size and shape
of a location in which it will be placed. For instance, if the
panel 08 is to be placed over an opening of a fluorescent troffer,
the panel 08 can be sized and shaped to cover the opening.
Accordingly, a person skilled in the art will recognize that a
common size for the thin panel 08 may be approximately 2 feet by
approximately 4 feet, which is similar to a size of a common
ceiling tile or fluorescent troffer. A thickness of the panel can
be thin, for instance in the range of about 1/32 of an inch thick
to about 1 inch thick, and in one embodiment it is about 1/8 of an
inch thick. Although in the embodiments described herein the panels
are generally described as covering an opening of a troffer or a
ceiling grid, in some embodiments it may be desirable to only cover
a portion of the opening of a troffer or a ceiling grid, and thus
the panels can be sized accordingly. The thin panel can be made of
any number of materials, including but not limited to plastic
and/or any commercially available polymeric resin. The thin panel
can be light weight, thin, and rigid enough to support the weight
of an LED module that will be integrated into it and support itself
in the ceiling grid. By making the thin panel light weight and
unobtrusive, the panel can be installed without requiring
accommodations or changes be made to the remaining ceiling
structure to support the thin panel and components, such as LED
modules, associated therewith.
[0089] With reference to FIG. 8, an illustration of multiple types
of LED modules is shown. The LED modules can include LED packages
mounted to a circuit board, as shown a printed circuit board (PCB)
06, and inserted into an extrusion, injection molded, or
thermoformed lens, which is typically, but not necessarily, plastic
that can aid in directing light from the LED packages in a certain
direction for light distribution control. While a person having
skill in the art would understand how to piece the components such
as the LED package, circuit board, and plastic piece together to
form an LED module, examples of LED modules that can be used in
conjunction with present disclosures are provided further
below.
[0090] In the illustrated embodiment, four differently shaped LED
modules are provided: a rectangular module 10, a hexagonal module
20, a triangular module 30, and an elliptical module 40, each of
which shows light 50 being emitted therefrom. A person skilled in
the art will recognize that any other number of shapes can be used
to form LED modules for use in conjunction with the devices,
systems, and methods provided for herein. Further, these modules
can be constructed from extremely efficient LEDs, for example
having a rating of 120 Lumens per Watt or greater, to minimize or
eliminate any need for significant thermal management to operate
properly. Once one or more LEDs are mounted to the PCB, any of
these modules can be used as the carrier for the light sources. The
modules may or may not include additional optics/diffusion for
focusing the beam of light or reducing glare or hot spots. The
module may also include screen type diffusion over the entire
module for both reduction in glare and attractive appearance of the
finished light panel. Additionally, the LED modules can be made
from any number of materials known to those skilled in the art,
including but not limited to polymers. In one exemplary embodiment
the entire LED module is made of plastic.
[0091] With reference to FIG. 9, illustrations of the LED modules
10, 20, 30, and 40 integrated to the thin panel 08 of FIGS. 7A and
7B are shown. Alternatively, the thin panel 08 can be a ceiling
tile in accordance with disclosures provided herein. The LED
modules can be integrated with the panel 08 in such a way that the
finished system looks cosmetically pleasing and has a rigid
reliable bond. As shown, in some embodiments a single LED module
10, 20, 30, 40 can be integrated with the panel 08 to form the LED
panel 60, while in other embodiments multiple LED modules 10, 20,
30, 40 can be integrated with the panel 08 to form the LED panel
70. A person skilled in the art will recognize that any number of
similarly or differently designed and shaped LED modules can be
mixed and matched to create the LED panel 70. A back side of the
LED panel 60, 70 can be flat, which can be helpful for retrofit
installations because it can generally sit directly below an
existing fluorescent fixture.
[0092] FIG. 10 illustrates one exemplary embodiment of an LED
module 100 and components related to the same. In the illustrated
embodiment the related components include an LED driver 80 and a
printed circuit board (PCB) 90. The LED module 100 can be mounted
on the PCB 90 and the driver 80 can be used to power the LED module
100. The LED driver 80 can be located in any number of locations
internal to or external of the LED module 100, including within the
LED module 100, within a panel, such as the panel 08 of FIGS. 7A
and 7B, adjacent to a panel, or remote from both the LED module and
the panel. In embodiments in which the LED module is placed over a
troffer, such as the troffers shown in FIGS. 2, 3, and 4, the
driver can be placed inside of the existing fluorescent troffer. In
some instances in which the driver is placed inside the LED module,
the resulting component can be compact and simple as a result,
thereby allowing an installer to take the finished LED panel and
wire it directly to the line power without having to separately
account for the driver. In some instances, however, it may be more
preferable to separate the driver from the LED module, for example
due to regulatory requirements, heat management, or weight or
physical dimensional constraints. In instances in which the driver
is disposed in a fluorescent troffer, the troffer can act as a
junction box for the conduit to enter into the fixture and
connections can be made in the sturdy, existing metal fixture
enclosure surrounding the ballast and wiring of the light
structure. Relying on an existing object like the troffer to act as
the junction box can be helpful in reducing additional weight or
forces applied to an installed thin panel or ceiling tile with
which the LED module is associated because it means a junction box
or like components are not separately associated with the panel or
ceiling tile. The LED module 100 can simply be an
extruded/injection molded or thermoformed part which LEDs are
mounted on, and the LEDs can be mounted on or slid onto the PCB 90.
A person skilled in the art will recognize that the LED module 100
can contain a number of features, including but not limited to
optics, reflectors, and diffusers, which can help create the proper
beam angles.
[0093] One exemplary embodiment of a linear optical body or cavity
for incorporation into an LED module that can be used in accordance
with the disclosures herein is shown in FIG. 11. Alternatively, the
linear optical body or cavity can also be used in conjunction with
other LED modules not necessarily described herein without
departing from the spirit of the present disclosure. This linear
optical body 240 can be the host to a circuit board with LEDs
mounted thereto, as described in further detail below. The linear
optical body 240 is configured such that it provides a distribution
of light in desired configurations, such as a bat wing
distribution, without the assistance of a secondary optics
component. The linear optical body 240 can be manufactured out of a
variety of materials known to those skilled in the art, including
but not limited to paper, metal, metal alloys, polymers, and
plastic. Further, the body 240 can have a variety of shapes, as
described in greater detail below, with the shapes being able to be
formed using any number of methods and processes known to those
skilled in the art, including but not limited to extrusion,
bending, and thermoforming. Accordingly, a person skilled in the
art will recognize that although the embodiments described herein
generally discuss the shapes associated with the body 240 being
complex parabolic bodies, other shapes can be used to create
desired light distributions without relying upon secondary optics
components to help control the resulting light distributions and
without departing from the spirit of the present disclosure.
Additionally, desired light distributions are not limited to bat
wing configurations. In view of the disclosures herein, a person
skilled in the art will recognize that the choices of placement of
the LEDs and the curvature and sizes of the walls of the optical
body can depend on a number of factors, including but not limited
to the desired light distribution, glare, and uses of the light
source, and that by adjusting the location of the LEDs and the
sizes and shapes of the walls of the optical body, different light
distributions can be created.
[0094] FIGS. 12A-12D illustrate one way by which a linear optical
body can be formed for use in conjunction with the LED modules
disclosed herein, as well as other LED modules known to those
skilled in the art, while FIG. 12E illustrates the configuration
that results from the steps associated with FIGS. 12A-12D, which
incidentally is the optical body 240 of FIG. 11. In the illustrated
embodiments, end caps of the body are removed to more clearly
illustrate different parts of its construction. As shown in FIGS.
12D and 12E, the linear optical cavity 240 can include two extruded
complex parabolic bodies 278 that have been rotated at an angle
.beta. 279 (FIG. 12E) from one another.
[0095] FIG. 12A illustrates a parabolic shape that is prescribed by
the mathematical relation of a parabola, y=4px.sup.2 where, as
shown, p 271 is the distance from the vertex 272 to the focal point
273 of the parabola 270 and x and y are the abscissa and ordinate
of an XY Cartesian plane. As shown, the parabola 270 has a left
branch and a right branch. Turning to FIG. 12B, the left and right
branches of the parabolic sidewalls 270 are separated when the two
branches 274 of the parabola are disconnected at the vertex 272,
separated and connected by a linear or curved line at a distance l
275. The geometrical shape that results is a complex parabola 276.
As illustrated in FIG. 12C, the complex parabola 276 can be
duplicated at one of the branches across a minor plane 260, thus
resulting in a second complex parabola. The minor plane can be a
central axis of the linear optical body, as shown in FIG. 12E. FIG.
12D illustrates these two complex parabolas in a displaced form, as
shown complex parabolas 278, configured in a manner such that they
are displaced from each other a distance .delta. 277. The two
parabolas are connected by a linear or curved line, as shown a
linear line, and thus a length of the line is also .delta. 277.
[0096] As illustrated in FIG. 12E, the two complex parabolas 278
can be rotated at an angle .beta. 279 around the z-axis, which is
perpendicular to the XY axis, such that the two straight lines 275
of the complex parabolas 278 are coplanar but not collinear (the
complex parabolas are subscript in the XY plane). In the illustrate
embodiment the two displaced complex parabolas 278 are rotated at
an angle .beta.=45.degree., as illustrated by central or extrusion
axes 281 of the first and second complex parabolas 278. A person
skilled in the art will recognize that other angles .beta. of
rotation are possible, including but not limited to angles
approximately in the range of about 15.degree. to about 60.degree.,
and that such angles can be selected to assist in creating
different light distributions. Once these two extended complex
parabolas 278 are extruded along the z-axis 261 perpendicular of
the XY plane, a surface of the extruded, extended complex parabolas
278 is formed, resulting in the complex parabolas 278 actually
being complex parabolic surfaces 278. Further, a thickness 262 can
be added to the extrusion. In such embodiments a solid,
three-dimensional object (linear optical cavity) 240 can be
formed.
[0097] A person skilled in the art will recognize that the
3-dimensional extruded optical cavity 240 can be made from a
variety of materials using a variety of different techniques,
including but not limited to a polymer or plastic extrusion,
thermal forming of a polymer or plastic, folding and other
manipulation of a paper box, metal or metal alloy bending, and
metal or metal alloy forming. Further, as described herein, a
person skilled in the art will recognize that the complex parabolas
276, 278 are used to demonstrate one of many possible shapes for
linear optical bodies to be used in conjunction with the present
disclosures. As described herein, a complex parabolic body is an
elongate body having a complex parabolic shape, deviating to the
extent as shown in illustrations for purposes of forming bottom
surfaces of the body (illustrated by lines 275 in FIG. 12E) and/or
for allowing one or more circuit boards, LEDs, and/or other
features to be mounted thereto.
[0098] FIG. 13 illustrates the linear optical body 240 having an
inner reflective surface located on inner walls or cavities 280.
The inner reflective surface can be created in a variety of ways,
for instance by including on the inner walls 280 a highly reflected
mirror finish, but in the illustrated embodiment a highly
reflective white diffuser 282 is coupled to the inner walls to
provide the desired inner reflection. In one exemplary embodiment
the reflectivity of the diffuser 282, or another reflective
component incorporated therein, is approximately equal to or
greater than about 95%. High reflectivity values can allow for
desired light distributions to be achieved, such as a bat wing
light distribution. In some embodiments the reflector can be a
coating applied to the inner walls 280, a coating sprayed on to the
inner walls 280, a film applied to the inner walls 280, or a sheet
that has been thermoformed or extruded and then applied to the
inner walls 280. Further, a light source can be incorporated into
the linear optical body 240. While the light sources can be
incorporated in a number of different manners, in one exemplary
embodiment a set of LED packages can be placed along the extrusion
axis of the complex parabolic reflector.
[0099] FIG. 14 illustrates the linear optical body 240 having a
linear LED light source 290 associated therewith. As shown, the
linear optical body 240 includes an inner reflective surface in the
form of the diffuser 282, and the light source 290 includes a
circuit board having LEDs mounted thereto. The light source 290 can
be associated with the body 240 using a variety of techniques known
to those skilled in the art. In the illustrated embodiment, the
body 240 is modified to include a channel for receiving the light
source 290, with the channel having a depth that allows the
diffuser 282 to sit flush with the top of the circuit board. This
can be advantageous because it can allow for the greatest amount of
internal space to be covered by the diffuser 282. Although the
illustrated embodiment includes two light sources 290, any number
of light sources can be mixed and matched with other light sources,
inner reflective surfaces, and other components within the spirit
of the present disclosure to create different light distribution
effects. As shown, no secondary optics components, including but
not limited to lenses, are provided. The present configuration
allows for broad-ranging light distributions without using
secondary optics components. However, secondary optics components
can be included in some embodiments if desired. To the extent
secondary optics components are included, they can be designed such
that they do not have a significant impact on the light
distribution provided by the light source. Alternatively, secondary
optics components can be included and can provide a further
variable relied upon for controlling light distribution.
[0100] FIGS. 15A-20B illustrate a number of different examples of
locations for light sources to be associated with linear optical
bodies in accordance with the disclosures herein. More
particularly, for each numbered figure, the FIG. A illustration
shows a side profile view of the optical body and associated light
source and the FIG. B illustration shows a light distribution that
results from the configuration illustrated in FIG. A. In accordance
with the disclosures herein, the light distribution that results
from the configurations provided depend on a number of factors,
including a size of the complex parabolic shape that forms the body
and the positioning of the light source, as shown LEDs, with
respect to the complex parabolic body. As demonstrated by the
teachings herein, there is in fact a unique correlation between the
rotated angle of the complex parabolic body and the LED linear
positioning along the extrusion axis of the complex parabolic body
that allows for a bat wing candela distribution to be created.
Other desirable types of light distributions can also be achieved.
In each of the examples shown in FIGS. 15A-19B, the collinear
extruded complex parabolic body 240' is rotated at approximately
45.degree., although other shapes and angles of rotation can be
used in other configurations without department from the spirit of
the present disclosure. In each embodiment, the LED placement is
illustrated using LED 290', and the resulting light distribution is
illustrated in the diagram 300'. The horizontal dotted line 302' on
the plots corresponds to a ceiling of a fixture. If the linear
light source is placed in a fixture, then the candela above the
horizontal dotted line means that part of the light will illuminate
the ceiling or top of the fixture. All of the resulting light
distributions may be desirable for different types of lighting
environments or purposes.
[0101] FIG. 15A illustrates the LEDs 290' at locations that are
equidistant on the respective base of each complex parabolic body
240'. This resulting light distribution shown in FIG. 15B can be
described generally as a wide bat wing configuration combined with
a central high intensity cone of light.
[0102] FIG. 16A illustrates the LEDs 290' at locations towards an
inside wall on the base of each complex parabolic body 240'. This
resulting light distribution shown in FIG. 16B can be described
generally as a wide bat wing configuration combined with a slight
central high intensity cone of light.
[0103] FIG. 17A illustrates the LEDs 290' at locations proximate to
the inside wall on the base of each complex parabolic body 240'.
This resulting light distribution shown in FIG. 16B can be
described generally as a very wide bat wing configuration.
[0104] FIG. 18A illustrates the LEDs 290' at locations towards an
outside wall on the base of each complex parabolic body 240'. This
resulting light distribution shown in FIG. 18B can be described
generally as a uniform Lambertian pattern.
[0105] FIG. 19A illustrates the LEDs 290' at locations on an inside
curved wall pointing inwards towards an outside curved wall of each
complex parabolic body 240'. This resulting light distribution
shown in FIG. 19B can be described generally as two lobes of light
with some upwards illumination combined with a sharp central high
intensity cone of light.
[0106] FIG. 20A illustrates the LEDs 290' at locations towards the
inside wall on the base of each complex parabolic body 240' now
rotated at an angle of .beta.=30.degree.. This resulting light
distribution shown in FIG. 20B can be described generally as a bat
wing configuration, with no central cone of light, which can result
in low glare levels directly under the module. The distribution
using a complex parabolic body rotated at approximately 30.degree.
can be useful in contexts such office space illumination.
[0107] FIG. 21 illustrates the linear optical body 240 associated
with the light source 290. The light source 290 can include a
circuit board 292 and a plurality of LEDs 294 mounted thereto. In
the illustrated embodiment, the light source 290 is mounted to the
body 240 in the same orientation as shown in FIG. 20A, and thus in
the LEDs 294 are positioned off-center, loaded towards an inner
side of the inner surface of the parabolic shape of the body 240,
and the complex parabolic shapes of the body 240 are rotated at
approximately a 30.degree. angle. This is configuration can be
useful as an LED module incorporated into a panel or ceiling tile
for use in a fluorescent troffer retrofit, replacement, or new
installation, as described in further detail below.
[0108] FIGS. 22A and 22B are directed to a glare reduction lens. In
particular, FIG. 22A illustrates one exemplary embodiment of a
glare reduction lens 310 and FIG. 22B illustrates one exemplary
embodiment of the lens 310 being incorporated into the linear
optical body 240 and with the light source 290 to form an LED
module 330. The glare reduction lens 310 can serve at least two
purposes. First, it can serve as a protective cover over the inner
cavity of the LED module formed by the body 240 and light source
290. In some instances the inner cavity 240 may need to be covered
to meet regulatory requirements (such as Underwriters Laboratories,
or UL) because there can be live circuitry inside the cavity, and
to serve as a protective cover of the inner cavity 240 so that a
reflective cavity associated therewith does not accumulate dust,
get wet, or otherwise get dirty, thereby keeping the high
reflectance of the inner cavity 240. Second, the glare reduction
lens 310 can be slightly frosted or diffused either in its entirety
or only in the area 320 (FIG. 22A) where the LEDs of the light
source 290 are placed under it. As a result, it can serve to reduce
glare because the LED sources will be less evident. It can be
desirable to only diffuse the portion of the lens 310 where the
LEDs of the light source 290 are located under it so as to not
unnecessarily reduce the optical efficiency of the LED light
source. In the illustrated embodiment, the glare reduction lens 310
does not substantially affect the light distribution emanating from
the light source 290. Thus, although the glare reduction lens 310
is an example of a secondary optics component, the light
distribution from the light source 290 is not the result of passing
light through a secondary optics component.
[0109] This lens 310 can be applied to the top surface of the
optical body 240 as shown using any number of techniques known to
those skilled in the art. By way of non-limiting examples, the lens
can slide, press, clip or be glued in place with respect to the
body 240. In some embodiments, the lens can serve a decorative
purpose. For example, it can be tinted a particular color(s). A
person skilled in the art will recognize that the combination of
the body 240 and the light source 290 can form an LED module for
use in the various systems, kits, and methods described herein
pertaining to retrofit and new light fixture installation.
Likewise, the additional features described herein, including but
not limited to the lens 310, an inner reflective surface such as
the diffuser 282, and covers, electronics, and wiring as needed,
can be incorporated into such LED modules. Such LED modules can be
associated with panels and ceiling tiles as described herein.
[0110] One illustration of the LED module 330 incorporated with the
thin panel 08 to form an LED panel 340 is shown in FIG. 23. The
association between the LED module 330 and the thin panel 08 can be
created in any number of ways, including using techniques described
herein. A person skilled in the art will recognize that the LED
module 330 can also be incorporated with the ceiling tile 09 if
desired to form a panel like the LED panel 120.
[0111] FIG. 24 illustrates the LED module 330 having fins
incorporated therewith. The fins 350 can be incorporated with the
LED module 330 using a variety of techniques, but in one embodiment
the fins 350 are extruded when the linear optical body or cavity is
extruded, i.e., the entire assembly can be a single extrusion. The
fins 350 serve can provide utility, and can also be configured to
add a decorative feature to the LED module 330. The fins 350 can be
useful because they can act as cut-offs for light emitting from the
LED module, for instance if further control of the light
distribution is desired. The fins 350 can be set to different
angles to achieve different variations of cut-off. The fins 350 can
designed to be decorative, for instance, by selecting a desired
size, shape, and/or material, by painting them, and/or by
laminating them. A person skilled in the art will recognize a
number of different ways by which the look of the fins 350, and
thus the module 330, can be enhanced. In one exemplary embodiment
the fins 350 are made from brushed aluminum vinyl, while in another
exemplary embodiment a wood laminate can be applied to the fins
350.
[0112] FIG. 25 illustrates a side view of the LED module 330 with
fins 350 and including an accessory mount or cover 360 mounted to
the panel 08. In the illustrated embodiment the accessory cover
extends above the LED module 360, and thus above the module's
linear optical body. Similar to the fins 350, the accessory cover
360 can be both decorative and useful. As shown, the cover 360 can
be mounted to the LED module by attaching to the fins 350. The
attachment can be made using any number of techniques known to
those skilled in the art, including by relying upon a mechanical
fit or an adhesive. The accessory cover 360 can assist to help
further reduce glare and/or control the light distribution of the
LED module 330. The cover 360 can be made from a variety of
materials, including but not limited to diffused material or
perforated material such as a screen or baffling. In some
embodiments, sideways emitting LEDs 370 can be mounted such that
they are recessed under the fins 350 to illuminate some of the top
side of the panel 340. Like any of the light sources disclosed
herein, the illumination can any number of colors, but in one
exemplary embodiment the color from the LEDs 370 is white. In some
embodiments, the illumination provided by the LEDs 370 may only
require a very small amount of electrical power, and thus can be
used, by way of non-limiting example, as emergency lighting. That
is, when the power goes out, the LEDs 370 of the module 330 can be
powered by a battery to provide emergency lighting for the
occupants of the space.
[0113] FIG. 26 illustrates one exemplary embodiment of an LED
module integrated into a thin panel or ceiling tile. In particular,
the LED module 100 is shown as being integrated into the panel 08
of FIGS. 7A and 7B. The LED module 100 can be integrated with the
panel 08 using any number of techniques known to those skilled in
the art, including by way of an adhesive or mechanical attachment
such as taping or ultrasonic welding. The entire assembly can be
described as an LED panel 110. A person skilled in the art will
recognize that other LED modules, including those of the nature
disclosed herein, such as the LED module 330 of FIGS. 23-25, can be
attached to the panel 08 to form an LED panel like the LED panel
110.
[0114] Although in FIG. 26 the component integrated with the LED
module 100 is the thin panel 08, a ceiling tile can be used in
place of the thin panel 08. One exemplary embodiment of such a
configuration is shown in FIG. 27. As shown, the LED module 100 is
integrated into a ceiling tile 09 on a front face of the tile 09 to
form an LED panel 120. The ceiling tile 09 can be any type of
commercially available ceiling tile, such as tiles manufactured by
companies like Armstrong or USG. A person skilled in the art would
understand a number of different sizes, shapes, and types of
ceiling tiles with which LED modules of the nature described herein
can be associated without departing from the spirit of the
disclosure. For example, a size of the ceiling tile 09 may be
approximately 2 feet by approximately 4 feet, which is a common
size for ceiling tiles. A thickness of the panel can be thin, for
instance in the range of about 1 inch to about 5 inches thick, and
in one embodiment it is about 3 inches thick. The LED module 100
can be integrated with the ceiling tile 09 using any number of
techniques known to those skilled in the art, including by way of
an adhesive or mechanical attachment such as taping or ultrasonic
welding. A person skilled in the art will recognize that other LED
modules, including those of the nature disclosed herein, such as
the LED module 330 of FIGS. 23-25, can be attached to the ceiling
tile 09 to form an LED panel like the LED panel 120.
[0115] In some embodiments it may be desirable to provide
additional support for the ceiling tile 09, for instance to account
for any structural strength compromised by virtue of coupling the
LED module 100 to the ceiling tile 09. For example, in instances in
which a slot or other cut is formed in the tile 09 to assist in
integrating the LED module 100 with the tile 09. The use of slots
or cuts, however, does not necessarily compromise the structural
strength of a ceiling tile 09, or a panel 08 for that matter. A
number of techniques known to those skilled in the art for
providing additional strength include providing reinforcement bars
or plates to the backside of the tile 09.
[0116] In the configuration shown in FIG. 27, additional components
of the lighting system include an LED driver 140 and a junction box
150. As shown, the LED driver 140 and the junction box 150 are
attached to the backside of the tile 09. A person skilled in the
art will recognize that it may be possible to secure the driver 140
and/or the junction box 150 to the tile 09. In the illustrated
embodiment the driver 140 and the junction box 150 are located
proximate to a back face of the tile 09, and the electrical
connections between the LED module 100 and the driver 140 and
junction box 150 are made through a hole 130 formed in the tile. As
also shown, the conduit can be brought into the junction box 150
through a hole 160. In other embodiments, the junction box 150 can
be located remotely or can have a disconnect system so that it is
wired first and then attached to the tile, thereby reducing the
risk of damaging the tile 09 when an installer attempts to position
the conduit, for instance by strong-arming it, and clamp it into
the junction box 150. Similar to the driver 80, the driver 140 can
be located in any number of locations internal to or external of
the LED module 100, including within the LED module 100, within the
tile 09, adjacent to the tile 09, or remote from both the LED
module 100 and the tile 09.
[0117] FIG. 28 is an illustration of one rectangular section 170 of
a ceiling grid. A person skilled in the art will recognize that a
ceiling grid typically includes a plurality of these rectangular
sections 170. The illustrated rectangular section 170 is
approximately 2 feet by approximately 4 feet, although other sizes
can be used, including other common configurations, such as
approximately 2 feet by approximately 2 feet, or less common
configurations or spacings. A plurality of "T-bars" 172, which are
generally commercially available, can be used to form the grid. The
T-bars 172 can either already be installed in the space or they can
be installed as part of the installation of the devices and systems
described herein.
[0118] FIGS. 29 and 30 illustrate the rectangular section 170 of a
ceiling grid in conjunction with an existing fluorescent fixture
180 and the LED panel 110. These views help illustrate one
non-limiting way in which components of the systems and devices
provided for can be installed in a retrofit scenario. The existing
fluorescent fixture 180 can be of any type, including but not
limited to the types described with respect to FIGS. 2, 3, and 4,
but in the illustrated embodiment the existing fluorescent fixture
180 is a prismatic troffer. In the case of an installation
involving a prismatic troffer, the enclosure door of fixture 180
can be swung open, thus allowing the prismatic lens to be removed.
Next, the LED panel 110 can be set in the door of the fixture 180,
electrical connections between the LED panel 110 and existing
electrical components can be made, and then the door can be closed
to complete the installation. In the case of any of the three types
of existing fixtures 180, one could also install the LED panel 110
between the ceiling grid 170 and the fixture 180. In one such
manifestation of this embodiment, the installer can first the
enclosure on the fixture 180 to access a ballast compartment, the
installer can make the necessary electrical connections between the
LED panel 110 and the other electrical components, and, if
necessary, the LED driver can be mounted.
[0119] Next, the installer can push up on the fixture 180 and slide
the LED panel 110 under the fixture but above the rectangular
section 170 of the ceiling grid. After the LED panel 110 is
aligned, the fixture 180 can be dropped back down on top of the LED
panel 170. The weight of the fixture 180 resting on the LED panel
170 can help ensure the LED panel 170 does not move. In some
instances, it may be easier to slide the LED panel 110 under the
fixture by accessing the space, for instance by moving a ceiling
tile next to the fixture 180. A person skilled in the art will
recognize a number of other variations to the steps that may occur,
for instance due to the particular configurations of the ceiling in
which the LED panel is being installed. Such variations are within
the spirit of the present disclosure.
[0120] FIG. 30 in particular helps to show the extreme low profile
of the LED panel 110 with respect to the total fixture height. In
fact, the height can remain virtually the same. As a result, the
support cabling to the building for the existing fluorescent
fixture 180 may not require any modification, such as shortening of
the cables.
[0121] FIG. 31 helps illustrate how the installation of the panel
110 can be carried out for a retrofit. The panel 110 used in the
installation can be selected based on a number of different
criteria, including but not limited to a desired size based on the
size of an opening with which it will be used. Thus, in the
illustrated embodiment, the selected panel 110 is sized to fit an
opening of the troffer of the existing fluorescent fixture 180. As
shown, the fluorescent fixture 180 can already be sitting on T-bars
172 of the ceiling grid. The LED panel 110 can be placed directly
between the fixture 180 and the T-bars 172. Any electrical
enclosures of the troffer of the fixture 180 can be removed,
thereby providing access to electrical components and connections.
This can allow the troffer to serve as a junction box. Electrical
connections can be made to the LED driver 140, wherever it may be
located, inside of the ballast compartment on the fixture. An
installer may wish to disconnect a line potential from a ballast of
the troffer is electrical power is running to it. In instances in
which the driver is disposed within an LED module of the LED panel
110, such electrical connections may not need to be made.
[0122] After the electrical connections are completed, one or more
portions of the previously removed electrical enclosures can be
re-installed to the fixture, and the LED panel 110 can be
positioned at or below a bottom portion of the troffer. The
resulting system is one in which a new LED module is used to
provide light while leaving the entire old fixture 180 in place. A
person skilled in the art will recognize a number of other
variations to the steps that may occur, for instance due to the
particular configurations of the ceiling in which the LED panel is
being installed. Such variations are within the spirit of the
present disclosure.
[0123] One exemplary embodiment of a mounting feature for use in
conjunction with installations such as those described herein, such
as installations of the panel 110, is shown in FIG. 32. As shown,
in some embodiments the LED panel 110 can have mounting features
111 that protrude outwards from sides of the panel 110. The
protrusions can assist in making the installation of the LED panel
110 easier to install in a ceiling grid, such as the ceiling grid
170, particularly when the original fluorescent fixture being
retrofitted is not perfectly seated in the ceiling. By not seating
perfectly in the ceiling, additional weight is transferred onto the
grid itself. The grids may not be designed to support the extra
weight, particularly if the additional weight is transferred by a
plurality of original fixtures. While in some retrofit scenarios
there may be a small vertical gap between the fixture and the grid
allowing the LED panel 110 to be slid between the two surfaces,
such a configuration is not always the case. Often the existing
troffer fixtures may have been installed in a way that the one or
more of the fixtures is sitting directly on the ceiling gird, and
thus some or all of its weight is also on the grid. In this
scenario, it would be difficult to install the new LED panel 110
without some type of modification to the support cables from which
the fluorescent fixtures hang. These cables can be modified, for
instance by shortening them, but doing so can require the installer
to open up the ceiling by removing ceiling tiles and carrying out
the modification. This scenario undesirably slows down the process
for installing a retrofit. The mounting features 111, however, can
speed up the retrofit process.
[0124] The mounting features 111 can designed in a way that they
are very thin, finger-like features that stick out transversely
from the panel 110. The extreme thinness of the features 111 allow
them to easily slide in between an existing fixture and the grid
even in instances in which the fixture is resting directly on the
grid. In some embodiments the mounting features 111 on one or both
sides of the panel 110 can be configured to have a sliding or
spring loaded action so that the installer can insert the features
on one side of the panel first, compress the features on that side,
which in turn can allow the features on the opposite side to easily
be inserted.
[0125] FIG. 33 helps illustrate how an installation of a new LED
panel, such as the panel 120, can be performed. The same ceiling
grid of FIG. 31, including the T-bars 172, is shown. In this
installation example, there is no existing fluorescent fixture. The
LED panel 120 used in the installation can be selected based on a
number of different criteria, including but not limited to a
desired size based on the size of an opening with which it will be
used. Thus, in the illustrated embodiment, the selected panel 120
is sized to fit an opening of the ceiling grid. The LED panel 120
can positioned in the ceiling grid at the T-bars 172 after any
electrical connections are made to bring the conduit into the
junction box 160 to provide power to the LED driver 140. In many
embodiments, the electrical connections will be disposed adjacent
to the ceiling grid, and can include a driver and/or a junction
box. The selected location of the ceiling tile can depend on a
variety of factors, including but not limited to where light is
desired and where the location of existing electrical connections,
such as junction boxes, may be. A person skilled in the art will
recognize a number of other variations to the steps that may occur,
for instance due to the particular configurations of the ceiling in
which the LED panel is being installed. Such variations are within
the spirit of the present disclosure.
[0126] FIG. 34 illustrates a ceiling grid with an LED panel 110,
120 installed. The LED panel 110, 120 can be below an existing
fluorescent fixture, or it can be part of newly installed ceiling
tile. The resulting installation is a very clean, pleasing look,
and as discussed above, an energy efficient one.
[0127] FIG. 35 provides for an LED module with a bulb screw base.
In this version of the design, a standard screw type (Edison style,
such as E12, E17, E26, E39, etc.) or pin type (GU10, G9, G24,
etc.), or any other type of lamp base shown in FIG. 37, can be
integrated onto the back side of the LED module 100. As a result,
the LED module 100 can be light enough in weight that it can easily
and safely be mounted to a lamp holder 200 that may be installed in
or on a ceiling 210 or junction box 220. A person skilled in the
art will recognize that this type of installation can be useful in
a variety of contexts, including homes or other buildings that do
not have drop down ceilings.
[0128] FIG. 36 illustrates an LED module having a built in control
system. The control system can have a number of different
configurations, including configurations known to those skilled in
the art, but in the illustrated embodiment the control system is a
photo sensor 230 integrated into the LED module 100. The photo
sensor 230 can be used to control a number of different features,
including but not limited to an on/off feature, motion detection,
or dimming of the LED module 100.
[0129] FIG. 37 illustrates a number of different examples of
standardized lamp bases that can be used in conjunction with the
various embodiments of the LED modules described herein. The
inclusion of these bases in no way limits the size, shape, and type
of bases or other components with which the LED modules described
herein can be used, but instead merely provides examples of the
types of lamp bases that can be effectively used in association
with the systems, devices, and methods described herein.
[0130] In one exemplary embodiment, a kit for installing a light
fixture can be provided. The kit can include either or both of one
or more of the thin panels 08 and the ceiling tiles 09, as well as
at least one LED module, such as the LED module 100, that can be
configured to be integrated with either or both of the panels 08
and tiles 09. Alternatively, or additionally, LED panels can come
preassembled with the LED modules 100 already associated with the
panels 08 and tiles 09, such as the LED panels 110 and 120. The kit
can further include an instruction manual that provides directions
complementary to the various installation methods described and
contemplated herein. For example, if the kit includes one or more
thin panels 08 and/or LED panels 110, the instruction manual can
provide directions for installing the panels 08, LED modules 100,
and/or the LED panels 110 over a preexisting light fixture, such as
a troffer. Likewise, if the kit includes one or more ceiling tiles
09 and/or LED panels 120, the instruction manual can provide
directions for installing the tiles 09, LED modules 100, and/or the
LED panels 120 in a ceiling grid.
[0131] A person skilled in the art will appreciate further features
and advantages of the disclosure based on the above-described
embodiments. The invention is not to be limited by what has been
particularly shown and described, except as indicated by the
appended claims. Accordingly, to the extent components and features
are described with respect to one form of light module, of
component thereof, or one method for installing or replacing a
light fixture, a person skilled in the art would understand how to
adapt these components and features across the various
configurations and embodiments provided herein. By way of
non-limiting example, the LEDs 370 that can be used for emergency
lighting purposes as described with respect to the LED module 330
of FIG. 25 can be incorporated to and adapted for any lighting
module provided for herein. All publications and references cited
herein are expressly incorporated herein by reference in their
entirety.
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